JPH09256255A - Nonwoven fabric, primary backing fabric for carpet, carpet and wall covering material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a primary backing fabric for a carpet excellent in characteristic balance among tufting and dyeing processabilities, dimensional stability, etc., excellent in characteristics such as pile surface grade or durability and rigidity, e.g. pile yarn withdrawal strength and a wall covering material excellent in right side printing characteristics and resin adhesion of the back surface. SOLUTION: This nonwoven fabric is a continuous filament nonwoven fabric comprising continuous filament web, composed of a low-melting polymer and a high-melting polymer and fixed by thermal fusion and has a difference in thermal adhesion strength between the face and back layers of the continuous filament nonwoven fabric. The primary backing fabric for a carpet is the continuous filament nonwoven fabric having 0.15-0.4g/cm<3> apparent density. The carpet comprises pile yarn tufted in the primary backing fabric for the carpet and has a backing layer formed with a resin or a nonwoven fabric. Furthermore, the wall covering material is the continuous nonwoven fabric having 0.2-0.55g/cm<3> apparent density thereof.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-woven fabric excellent in tufting processability, strength of pile fabric tufted with pile yarns, processability during carpet production such as dyeing processability, and dimensional stability, especially for carpets. The present invention relates to a carpet excellent in durability and rigidity such as surface quality of base cloth and pile surface and pull-out strength of pile yarn, and a wall material excellent in surface printability and resin adhesion on the back surface.

[0002]

2. Description of the Related Art Currently, as a primary fabric for carpets,
Polypropylene film slit yarn woven fabric, jute base fabric, spunbonded long fiber non-woven fabric and the like are used. Among them, primary base fabrics for carpets using long-fiber nonwoven fabrics by the spunbond method are increasing due to advantages such as pile yarns having good orderliness and no fiber fraying. For example, Japanese Patent Publication No. 61-8189. As proposed in 1), a thermoplastic synthetic resin is melted by heating, extruded from a spinneret having a large number of pores, sucked and stretched by an ejector that sucks at high speed, and the filaments are collected on a moving net. After that, the fibers are mechanically entangled with each other by needle punching and further bonded to each other with an adhesive, and a non-woven fabric for carpet, and JP-A-3-1.
A non-woven fabric for carpet obtained by thermocompression bonding with an embossing roll, using a core-sheath composite fiber in which polyethylene terephthalate as a core component and a low melting point component covers the entire surface of the fiber, which is proposed in Japanese Patent No. 04973. In the production of a non-woven fabric having an orthogonal structure in which polyester filaments are folded back and laminated in the length direction and the width direction, which is proposed in Japanese Patent Publication No. 3-17948, a copolyester having a melting point lower than that of the polyester filament in the preceding period is used as an adhesive component. After mixing with the polyester filament into a comb shape before supplying to the air jet device,
Nonwoven fabrics for carpets that are heat-welded through a heat cylinder are used.

In tufted carpets, pile yarns are tufted on these primary base fabrics by using a tufting machine to form a so-called pile fabric, and the pile yarns are dyed by a loop steamer type continuous dyeing machine or the like. Then, by using various resins such as vinyl chloride resin paste, styrene-butadiene rubber (SBR) resin, ethylene-vinyl acetate copolymer resin, etc. on the back side of the pile fabric, or by needle punching the non-woven fabric without using the resin. Backed and manufactured. Among the tufted carpets, the tile carpet is manufactured by cutting into a tile shape such as a 50 cm square after a resin backing or the like.

Further, as the wall material, a non-woven fabric manufactured by a spunbond method or the like, on which printing such as printing or gravure printing is applied, is used.

[0005]

Such a primary carpet base cloth for carpets, for example, has good tufted pile yarn orderliness, the fibers of the base fabric do not float on the surface layer of the pile yarn, and the pile gripping force is high. It is excellent in skipping phenomenon and pile loss, has little width shrinkage due to process tension in the dyeing process, has excellent thermal dimensional stability in the backing process, and fluff occurs from the cross section of the base fabric during cutting. It is required to have excellent workability and low price. Further, the required characteristics that can be used as a carpet include durability such as pile yarn pull-out strength and rigidity.

However, in the conventional primary carpet base carpet, the fibers are mechanically entangled by, for example, needle punching, and then an adhesive such as an emulsion binder is applied to bond the fibers to obtain the primary carpet primary carpet. The base cloth is expensive because it requires a needle punching process and a drying process for the emulsion binder.
In addition, since the thickness is large, the amount of pile yarns used increases, which causes problems such as the weight of the carpet being heavy and the cost being high.Moreover, the high melting point component is the core part and the low melting point component is the sheath. The primary base cloth for carpet obtained by thermocompressing the web obtained from the core-sheath type composite fiber used for the part with an embossing roll has a tendency to firmly adhere because all the fibers are adhesive fibers. Sometimes the tuft needle increases the penetration resistance of the base fabric, as a result of which the fiber of the base fabric is likely to be cut, the tendency for the strength of the pile fabric to decrease, and there is a problem that the noise increases, and there is a problem with the high melting point component fiber. The primary base cloth for carpet obtained by thermocompressing the web obtained by mixing the low melting point component fibers with an embossing roll, etc. When the tuft is low, the fibers of the base fabric are apt to be pushed out to the surface layer of the pile yarn by the tuft needle during the tufting, and the quality of the carpet tends to be poor.In addition, the processing tension under wet heat conditions during passage through the loop steamer during continuous dyeing is low. As a result, the dimensional change becomes large and the specified width of the carpet cannot be obtained, resulting in poor yield of the product. Conversely, if the ratio of low melting point component fiber is large, the fiber is likely to be cut by the tuft needle during tufting, and the high melting point. Since the number of constituent fibers is reduced and the number of adhesion points between fibers is reduced, it is difficult to obtain a plurality of required properties in each process in a well-balanced manner, such as the strength of the base fabric that can withstand processing cannot be obtained. It is difficult to obtain satisfactory processability in all steps of carpet manufacturing, such as dyeing processability and dimensional stability. What is used in a range that can compromise the processability and properties in the were present.

Further, a conventional carpet, for example, a tufted carpet obtained by using a primary base cloth for a tufted carpet, is a primary base cloth in which a non-woven fabric is bonded between fibers by an adhesive, or a core-sheath type composite fiber. The tufted carpet obtained by using the primary base fabric composed of only the backing resin is appropriately bonded to the primary base fabric because the surface fibers located on the backing side of the primary base fabric are firmly bonded and smooth. Since it does not penetrate into the cloth, the adhesion between the primary backing and the backing layer is insufficient, and the durability such as insufficient pulling strength of pile yarn such as abrasion due to long-term walking or use of a chair with casters and pulling out of the pile can be satisfied. Was not.

[0008] Further, since the wall material using the conventional non-woven fabric attaches great importance to the surface printing property and is firmly finished by the interfiber bonding firmly to the front and back layers, the non-woven fabric is pasted on the wall with resin. In this case, the adhesive strength at the interface between the non-woven fabric and the resin was small, and in some cases, the non-woven fabric was peeled off.

In view of such conventional non-woven fabrics, especially primary base fabrics and wall materials for tufted carpets, the present invention has well-balanced characteristics such as tufting processability, dyeing processability and dimensional stability, and moreover, tufted carpets. Durability such as pile surface quality and pile thread pullout strength after being manufactured in
The primary object of the present invention is to provide a carpet primary carpet and a carpet having excellent characteristics such as rigidity, and a wall material having excellent surface printing characteristics and resin adhesion on the back surface.

[0010]

The present invention employs the following means in order to solve the above-mentioned problems.

That is, the non-woven fabric of the present invention is a long-fiber non-woven fabric in which a long-fiber web composed of a low-melting polymer and a high-melting polymer is fixed by heat fusion, and heat-bonded to the front and back layers of the long-fiber non-woven fabric. It is characterized by providing a difference in strength, and the primary carpet base fabric of the present invention,
This nonwoven fabric is characterized in that the apparent density of the long fiber nonwoven fabric is 0.15 to 0.4 g / cm ³ . Further, the carpet of the present invention has pile yarn tufted on the primary carpet base fabric,
The wall material of the present invention is the above-mentioned non-woven fabric, and the apparent density of the long-fiber non-woven fabric is 0.2.
It is characterized by being ~ 0.55 g / cm ³ .

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention has well-balanced characteristics such as tufting processability, dyeing processability, and dimensional stability to obtain satisfactory processability in all steps of manufacturing tufted carpets. After carefully studying whether it is possible to provide a primary carpet base fabric that is also excellent in pile surface quality and durability after being manufactured in accordance with each characteristic for each manufacturing process and product, It has been clarified that the above-mentioned requirements can be satisfactorily achieved by allowing the surface layer and the back layer of the long-fiber nonwoven fabric to have a well-balanced function. In addition, an analysis of this non-woven fabric surprisingly revealed that it has suitable properties as a wall material.

That is, the basic idea of the present invention is
A long-fiber web composed of a low-melting polymer and a high-melting polymer is provided with a thermal adhesive strength difference between the front and back layers of a long-fiber nonwoven fabric fixed by heat fusion, and is suitable for the functions of primary carpet base cloth and wall material. It has a specific apparent density. In other words, by increasing the heat-bonding strength of the surface layer of long-fiber non-woven fabric, it imparts strength and dimensional stability that can withstand processing, increases the rigidity of carpet products, and further arranges the surface layer of long-fiber non-woven fabric on the pile side. By suppressing the fluff from the non-woven fabric generated on the pile surface, it is possible to bring about an excellent carpet surface quality, and by suppressing the thermal adhesive strength of the back layer of the long fiber non-woven fabric to be lower than the surface layer, Properties that cannot be obtained by function, such as the resistance to penetration of the base fabric by the tuft needle at the time of tufting, the suppression of fiber cutting and the imparting of pile gripping force due to the entanglement with the pile yarn, and the tuft processing due to the low thermal adhesive strength. The fibers become web-like and become a low density non-woven fabric layer, and by arranging them on the backing side, it gives appropriate backing resin permeability and anchor effect. It is possible to bring out the adhesion effect with the backing layer and to exert durability such as the pile pull-out strength of the carpet. Due to the synergistic effect of the front and back layers of these long-fiber nonwoven fabrics, each nonwoven fabric layer has its own Since it has well-balanced functions, it is possible to provide a primary base fabric for carpet that obtains satisfactory processability in all steps during carpet production, and a carpet obtained using such a primary base fabric has excellent carpet surface quality. It is possible to provide a carpet, particularly a tufted carpet, which is durable enough to withstand long-term walking and use of a chair with casters.

Surprisingly, the characteristics of the front and back layers of this long-fiber nonwoven fabric are similar to those of the wall material. That is,
By increasing the heat-bonding strength of the surface layer of the long-fiber non-woven fabric, the surface printing characteristics such as printing and gravure printing are excellent, and by suppressing the heat-bonding strength of the back layer of the long-fiber non-woven fabric to be lower than that of the surface layer, the non-woven fabric is made into wood. When using resin adhesive to attach to walls such as or concrete,
The resin adhesive easily penetrates into the non-woven fabric, and the fibers of the non-woven fabric backing layer play the role of anchors, so that excellent adhesive performance can be obtained. What can be provided.

In order to obtain these functions, it is preferable that the thermal bonding strength of the surface layer of the long fiber non-woven fabric is such that the abrasion strength measured according to the Taber method of the abrasion strength test of JIS L-1906 is class 3 or higher. , More preferably 3.5 or higher, particularly preferably quaternary or higher. When the abrasion resistance of the surface layer of the long fiber non-woven fabric is less than grade 3, the thermal adhesive strength is low, so when it is used as a primary base fabric for tufted carpet, the strength that can withstand the processing tension is not obtained and the width during processing is reduced. There is a problem that shrinkage occurs, the product specified width is not obtained, yield is deteriorated, necessary rigidity is difficult to obtain, fibers from the nonwoven fabric are raised on the pile surface, and so-called fluff occurs. It is not preferred because it occurs, and when used as a wall material, it is difficult to obtain surface smoothness, ink bleeding easily occurs at the time of printing or printing, and fibers are fluffy when used for a long period of time. It is not preferable because the appearance is easily damaged.

The thermal adhesive strength of the backing layer of the long fiber non-woven fabric is preferably 3 or less, more preferably 1 or less, as measured by the Taber method of the JIS L-1906 abrasion strength test. Grade 5 or higher and grade 3 or lower, particularly preferably 2
It is preferable that the grade is 2.5 or more and 2.5 or less. When the abrasion strength of the backing layer of the long fiber non-woven fabric exceeds Class 3, as a result of the high thermal adhesive strength, the non-woven fabric becomes too hard and is used as the primary base fabric for tufted carpet. There is a tendency for the cloth penetration resistance to increase and the noise to increase, and for fiber cutting of the non-woven fabric to occur and the strength of the pile fabric after tufting to decrease, resulting in large dimensional changes during processing, and in some cases sheet breakage during processing. It causes problems such as insufficient penetration of backing resin at the time of backing and causes poor durability such as pile pull-out strength of tufted carpet, which is not preferable. Is too smooth, it is difficult for the resin adhesive to penetrate into the nonwoven fabric when it is attached to a wall such as wood or concrete with a resin adhesive, Undesirable because it is difficult to obtain a partial adhesion.

More preferably, the difference in the thermal adhesive strength between the surface layer and the back layer of the long fiber non-woven fabric is at least 0 when expressed by the abrasion strength measured according to the Taber method of the abrasion strength test of JIS L-1906. A grade of 5 or higher is preferred because the above function can be shared between the surface layer and the back layer of the long fiber non-woven fabric in a well-balanced manner, and the difference in thermal bonding strength from the surface layer to the back layer of the long fiber non-woven fabric is particularly preferred. It is preferable to have a graded adhesive strength gradient over time.

In order to provide a thermal adhesive strength difference between the front and back layers of the long fiber non-woven fabric, in particular, the front layer has a wear resistance of grade 3 or higher, and the back layer has a wear strength of grade 3 or lower. It is preferable to use a non-woven fabric structural form. In addition, about the structural form of the nonwoven fabric mentioned below, you may use independently and it is more preferable to combine two or more.

First, it is preferable that the low melting point polymer content ratio of the surface layer of the long fiber non-woven fabric is higher than the low melting point polymer content ratio of the back layer. The high melting point polymer and the low melting point polymer have a ratio of 90:10 to 60:40, and the backing layer has a high melting point polymer and the low melting point polymer of 95: 5 to 70:30.
It is particularly preferable that the ratio of the high melting point polymer to the low melting point polymer in the surface layer of the long fiber non-woven fabric is 8
It is preferable that the ratio of the high melting point polymer and the low melting point polymer in the back layer is 5:15 to 70:30 and 90:10 to 80:20. If the low melting point polymer content ratios of the front and back layers of the long fiber non-woven fabric are the same, it becomes difficult to provide a thermal adhesive strength difference between the front and back layers.

When the content of the low melting point polymer in the surface layer of the long fiber non-woven fabric exceeds 40%, the polymer melts during heat fusion and the entire sheet tends to form a film, resulting in resistance to penetration of the base fabric during tufting. In addition to the tendency to increase, it is not preferable in terms of price, and conversely the low melting point polymer content ratio is
If it is less than%, it tends to be difficult to obtain a wear strength of grade 3 or higher, thermal adhesion between fibers tends to be insufficient, and it is difficult to obtain the required sheet strength, and fuzz is likely to occur on the pile surface. An unfavorable tendency such as is caused.

If the ratio of the low melting point polymer in the back layer of the long fiber non-woven fabric exceeds 30%, the interfiber adhesion becomes too strong, and it tends to be difficult to obtain a wear strength of class 3 or less, and the fibers at the time of tufting In addition to easy breakage, it is easy to increase the density and resin penetration is likely to be insufficient. Conversely, if the ratio of the low melting point polymer is less than 5%, it is difficult to obtain the adhesive strength required for maintaining the shape of the nonwoven fabric. In addition, the sheet itself is fluffed during processing, and the sheet tends to be liable to be fluffed, and fluff fibers may be wrapped around a roll or the like.

Secondly, it is preferable that the low melting point polymer contained in the surface layer of the long fiber nonwoven fabric has a lower melting point than the low melting point polymer contained in the back layer.

If there is no difference between the melting point of the low melting point polymer contained in the surface layer of the long fiber non-woven fabric and the melting point of the low melting point polymer contained in the back layer, it tends to be difficult to obtain a difference in thermal bonding strength between the front and back layers. . In particular, in order to make the difference in thermal adhesive strength between the front and back layers of the long-fiber non-woven fabric as at least 0.5 grade when expressed by the abrasion strength measured according to the Taber method of the abrasion strength test of JIS L-1906. More preferably, the melting point of the low melting point polymer contained in the surface layer of the long fiber non-woven fabric is 5 to 50 ° C. lower than the melting point of the low melting point polymer contained in the back layer,
Particularly preferably, the polymer is 10 to 30 ° C. lower.

The melting point of the low melting point polymer is preferably 20 to 80 ° C., which is lower than the melting point of the high melting point polymer,
More preferably, it is 30 to 50 ° C. If the melting point difference between the low melting point polymer and the high melting point polymer is less than 30 ° C, the inter-fiber adhesive strength tends to be insufficient, and if the melting point difference exceeds 80 ° C, fiber spinning during nonwoven fabric production Spinning defects such as single yarn breakage due to time instability are likely to occur.

Thirdly, the fineness of the single fibers constituting the surface layer of the long-fiber non-woven fabric is smaller than the fineness of the single fibers constituting the back layer, so that the number of interfiber adhesion points in the front layer increases and the front and back layers It is preferable because the difference in the heat adhesion strength can be provided.

At this time, the fineness of the single fiber is preferably 2 to 15 denier, more preferably 6 to 10 in view of suppressing fiber breakage during tufting and strength of the non-woven fabric when used as a primary base fabric for carpet. Denier is preferable, and when the fineness of the single fiber is less than 2 denier, the tuft needle during tufting tends to cause fiber breakage, tending to reduce the strength of the pile fabric. This is because the number of constituent fibers decreases and the number of bonding points between fibers tends to decrease, which makes it difficult to obtain strength that can withstand processing, and when used as a wall material,
From the viewpoint of spinnability during the production of a nonwoven fabric and printing characteristics as a wall material, 0.5 to 6 denier is preferable, and 1 to 3 denier is more preferable.

Among them, the long-fiber non-woven fabric has such characteristics that the surface layer has a wear strength of grade 3 or higher and the back layer has a wear strength of grade 3 or lower,
The difference in the thermal adhesion strength between the front and back layers is at least 0.5 grade when expressed by the abrasion strength measured according to the Taber type method of the abrasion strength test of JIS L-1906, preferably for carpet. In the case of the primary base cloth, the fineness of the single fibers constituting the surface layer is preferably 4 to 7 denier, and the fineness of the single fibers constituting the back layer is preferably 7 to 12 denier, and in the case of the wall material, the surface layer is constituted. The fineness of single fiber is 1-2 denier,
The fineness of the single fibers constituting the back layer is preferably 3 to 5 denier.

Fourthly, the surface layer of the long fiber non-woven fabric is a non-woven fabric layer (A) composed of a core-sheath type composite fiber having a core of a high melting point polymer and a sheath of a low melting point polymer, and a back layer of a high melting point polymer. It is preferable that the non-woven fabric layer (B) composed of a mixed fiber of the following fiber and the fiber of the low melting point polymer is laminated. In other words, the surface layer is a non-woven fabric layer (A) in which all the fibers are composed of core-sheath type composite fibers having a function as a heat-bonding fiber, and therefore, compared with a non-woven fabric layer (B) composed of mixed fibers in the back layer. This is because the thermal adhesive strength can be easily obtained, and the thermal adhesive strength difference between the front and back layers of the long fiber nonwoven fabric can be easily obtained.

At this time, the non-woven fabric layer (A) and the non-woven fabric layer (B)
The basis weight ratio is 1 when used as a primary carpet base fabric.
0:90 to 60:40 is preferable, and more preferably 3
It is 0:70 to 50:50. When the basis weight ratio of the nonwoven fabric layer (A) composed of the core-sheath type composite fiber is less than 10%,
The total adhesive strength of the base cloth becomes low, the strength that can withstand the processing tension is not obtained, and width shrinkage occurs during processing, the product specified width cannot be obtained, leading to deterioration of yield, and it becomes difficult to obtain the required rigidity. Also, problems such as fluffing on the pile surface tend to occur, and conversely, when the basis weight ratio of the non-woven fabric layer (A) exceeds 60%, the base fabric becomes too hard, resulting in a base during tufting. There is a tendency for the cloth penetration resistance to increase and the noise to increase, and for fiber cutting to occur and the strength of the pile fabric after tufting to decrease. Further, the weight ratio of the non-woven fabric layer (A) and the non-woven fabric layer (B) when used as a wall material is
30:70 to 95: 5 are preferable, and 5 is more preferable.
It is 0:50 to 80:20. When the basis weight of the nonwoven fabric layer (A) composed of the core-sheath type composite fibers is less than 30%,
It tends to be difficult to obtain the surface smoothness of the surface layer, and when the basis weight ratio of the nonwoven fabric layer (A) exceeds 95%, the surface of the back layer tends to be too smooth, and the adhesiveness with the resin adhesive is observed. Tends to be difficult to obtain.

In the present invention, in order to strengthen and integrate the layers between the non-woven fabric layer (A) and the non-woven fabric layer (B), needle-punching treatment is applied to the non-woven fabric layer (A) before heat fusion. ) And the fibers existing between the layers of the non-woven fabric layer (B) may be entangled. In this case, more preferably, in order to suppress the generation of fluff on the pile surface after tufting, needle punching is preferably performed from the surface side of the nonwoven fabric layer (A).

Fifth, it is preferable that the fibers of the long fiber non-woven fabric are bonded and fixed by a resin binder, and a difference in the concentration gradient of the resin binder is provided between the front and back layers.

As a method of providing a difference in concentration gradient of the resin binder between the front and back layers of the long fiber non-woven fabric, a method of impregnating the emulsion type resin binder and then drying the resin binder while migrating the resin binder to the surface layer side, an emulsion type resin binder It is possible to use a method of spraying from the surface layer side of the long fiber non-woven fabric, applying with a roll, applying with a doctor knife, and then drying.

Examples of the resin binder include acrylic ester resin, vinyl acetate resin, ethylene-vinyl acetate copolymer resin, vinyl chloride resin, polyester resin, styrene-butadiene rubber, methyl methacrylate-butadiene rubber, acrylonitrile- Butadiene rubber or the like can be used.

At this time, the amount of the resin binder applied to the long-fiber nonwoven fabric is preferably 5 to 30% by weight from the viewpoint of strength, feeling and the like.

Sixth, in the heat fusion method for providing a difference in thermal bonding strength between the front and back layers of the long fiber nonwoven fabric, a pair of embossing rolls are used to provide a temperature difference between the upper and lower rolls and the surface layer side of the long fiber nonwoven fabric is used. It is preferable to increase the temperature of No. 2 or to apply hot air from the surface layer side using a suction drum.

When an embossing roll is used, the pressure-bonding area is preferably 5 to 30%, more preferably 15 to 25.
%. When the pressure-bonding area is less than 10%, it is difficult to obtain sufficient strength to withstand processing because the bonding area is small, and when the pressure-bonding area exceeds 30%, the entire sheet tends to be bonded and formed into a film. This is because the problem of increased penetration resistance of the base cloth is likely to occur.

Further, when used as the primary base fabric for carpet, the apparent density of the long fiber nonwoven fabric is 0.15 to 0.
It should be in the range of 4 g / cm ³ , and more preferably,
It is preferably in the range of 0.22 to 0.3 g / cm ³ .
If the apparent density of the long fiber non-woven fabric is less than 0.15 g / cm ³ , the thickness tends to be too thick, and when the pile yarn is tufted, the pile yarn is used to obtain the required pile height. However, if the apparent density of the long-fiber nonwoven fabric exceeds 0.40 g / cm ³ , the resistance to penetration of the base fabric by the tuft needle during tufting increases and noise increases. This is not preferred because the tendency is insufficient and the backing resin does not sufficiently penetrate into the base fabric during backing, so that the pile pull-out strength of the carpet tends to be insufficient.

When it is used as a wall material, the apparent density of the long fiber non-woven fabric needs to be in the range of 0.2 to 0.55 g / cm ³ , and more preferably 0.25 to 0.5 g. /cm
It is preferably in the range of ³ . If the apparent density of the long-fiber non-woven fabric is less than 0.2 g / cm ³ , the density will be too low, and ink bleeding will tend to occur during printing. When the density exceeds 0.55 g / cm ³ , the texture becomes too hard and wrinkles and the like tend to occur during the work of sticking to the wall, which is not preferable.

The high melting point polymer used in the present invention may be any polymer such as polyester, polypropylene, polyamide, polyethylene, etc., but in view of high strength, thermal dimensional stability, weather resistance, etc. Polyethylene terephthalate is preferably used. Also,
As the low-melting point polymer, any polymer such as polyester, polypropylene, polyamide, and polyethylene may be used, but adipic acid copolymerization is performed from the viewpoints of spinning stability during production of nonwoven fabric and uniformity of sheet weight due to jet collision plate charging. Copolyesters such as polyesters and isophthalic acid copolyesters are preferred.

If necessary, a smoothing agent such as polydimethylsiloxane may be added to the primary carpet base fabric of the present invention to suppress fiber breakage during tufting.

By using the primary base cloth for carpet obtained as described above, tufting pile yarns and backing with a resin or a non-woven fabric, a surface layer having particularly high heat-bonding strength is provided on the pile side for comparison. By placing a backing layer with low thermal density and low thermal adhesive strength on the backing side, a carpet with no fluff on the pile surface and durability such as pile pull-out strength, and a carpet with excellent rigidity, especially tufted carpet and You can get a tile carpet. Further, when it is used as a wall material, it is preferable to have a resin adhesive layer on the back layer side of the long fiber non-woven fabric in order to easily carry out the bonding work to the wall.

[0042]

The present invention will be described in more detail with reference to the following examples.
It goes without saying that the present invention is not limited only to the following embodiments. In addition, the evaluation method of each characteristic in an Example is as follows.

(1) Apparent density of long-fiber non-woven fabric The thickness of the long-fiber non-woven fabric was photographed with a scanning electron microscope (SEM) at a magnifying power of 100 times to photograph a cross-section of the thickness of 1 m ^2.
The average value obtained by measuring 20 points in the thickness direction per contact with a caliper was calculated by calculating the thickness from the magnification and the apparent density was calculated by the following formula.

(Apparent density) = (Unit weight of long-fiber non-woven fabric) /
For (long fiber thickness average value of the non-woven fabric) (2) abrasion strength front and back layers of the long-fiber nonwoven fabric, measured according to the Taber form method abrasion strength test of JIS L-1906 ^-1994, 0.5 grade units It was evaluated by.

[0045] (3) was measured according to the tensile strength JIS L-1906 ^-1994 of the long-fiber nonwoven fabric. In addition,
The longitudinal direction of the nonwoven fabric is described as vertical and the width direction is described as horizontal.

(4) 44 tuft needles (22 staggered two-row stagger, needle type; made by Organ Co., Ltd.) KPE-41)
Is set in a constant-speed extension type tensile tester and the speed is 20 cm / min.
The maximum load when vertically piercing the primary base fabric (nonwoven fabric) for tufted carpet was measured.

When the maximum load at this time is less than 18 kgf, ○,
Evaluation was made with 18 kgf to less than 23 kgf as Δ, and 23 kgf or more as x. (5) Tensile strength of pile fabric Using a tufting machine, pile yarn (nylon BCF, 2600 denier 160 filaments) is 1/10 gauge and stitches 12 on the primary fabric for tufted carpet.
This / inch, after obtaining a pile fabric with tufted looped pile height 3.5 mm, was measured according to JIS L-1906 ^-1994. In addition, the longitudinal direction (tuft direction) of the primary base fabric for tufted carpet was described as vertical, and the width direction was described as horizontal.

(6) Dimensional stability during continuous dyeing The pile fabric obtained in (5) above was dyed with a loop steamer type continuous dyeing machine to dye the pile yarn, and the width dimension change (width) in the width direction before and after dyeing (width) Shrinkage) was measured.

The width shrinkage is {(width before dyeing-width after dyeing) / width before dyeing} × 100 (%). Less than 8% was evaluated as ◯, 8 to 10% was evaluated as Δ, and 10% or more was evaluated as x.

(7) Surface Quality of Tufted Carpet The presence or absence of fluff generated from the base fabric on the surface layer of the pile yarn of the dyed pile fabric obtained in (6) above was visually determined. Good quality with no fluff
The case where slight fluffing was recognized was evaluated as Δ, and the case where fuzzing was remarkable and the quality was poor was evaluated as x. (8) Pile pull-out strength of tile carpet Using a tile carpet obtained by backing the back surface of the dyed pile fabric obtained in (6) above with a vinyl chloride resin paste, JIS-L1023 ^-1992 The measurement was performed according to the case of the loop pile of the pile pull-out strength test. If the pile pull-out strength is 3.0 kgf or more, it is ○, 2.5 to 3.0 kgf is △, and less than 2.5 kgf is ×.
Was evaluated.

(9) Rigidity of tile carpet Using the tile carpet obtained by backing the back of the dyed pile fabric obtained in (6) above with a vinyl chloride resin paste, JIS L-1906 ^-1994
The measurement was carried out according to the 45 ° cantilever method of the bending resistance test.

(10) Printability of wall material The surface of the long-fiber non-woven fabric was subjected to grid pattern red single-color printing by the offset gravure printing method, and the printability was visually evaluated.
The printed line having no bleeding and good ink paste was evaluated as ◯, the printed line having some bleeding was evaluated as Δ, and the marked line having remarkable bleeding was evaluated as x.

(11) Resin Adhesiveness of Wall Material Vinyl acetate resin emulsion (viscosity of about 200
0 cps) was applied, the back layer surface of the long fiber non-woven fabric was adhered and dried, and then the state of adhered fibers in the resin layer when the long fiber non-woven fabric was peeled off was visually determined. In addition, for those having a resin adhesive layer on the back layer of the long fiber non-woven fabric in advance, after directly adhering to the plywood and left to stand, the state of fiber adhesion remaining on the resin when the long fiber non-woven fabric was peeled off was visually determined. .

The fibers that did not peel off at the interface between the long-fiber nonwoven fabric and the resin adhesive layer and were peeled off at the interface between the resin layer and the plywood were marked with ⊚, those that adhered entirely to the resin layer were marked with ◯, and the fibers remaining in the resin layer were marked with ◯. The adhesion area ratio of 50% or more was evaluated as Δ, and the fiber adhesion area ratio of the resin layer remaining less than 50% was evaluated as x.

Examples 1 to 3 Polyethylene terephthalate having a melting point of 262 ° C. was used as a high-melting polymer and isophthalate having a melting point of 225 ° C. was used by using a spinning / fabric making apparatus capable of jet-laminating two layers of fiber webs before and after. The acid-copolymerized polyester was used as a low melting point polymer and melted at 285 ° C., and then the spinneret had a spinneret hole diameter of 0.
A large number of high-melting point polymer fibers and low-melting point polymer fibers with 5 mmφ and 30 holes are arranged, and the weight ratios of the high-melting point polymer and low-melting point polymer in the front and back layers of the long fiber web are respectively (1) Surface layer 85: 1
5, back layer 85:15, (2) surface layer 80:20, back layer 8
5:15, (3) The molten polymer was extruded and cooled so that the surface layer was 80:20 and the back layer was 90:10. Then, the single yarn denier was pulled at a high speed by an ejector so as to be 8 denier, and lead was mainly contained. Charged by the colliding plate, opened the filament bundle, then jetted on the moving net conveyor,
It was collected with a width of 4.3 m. Subsequently, a pair of embossing rolls having a pressure bonding area of 18% were used to set the roll temperature to 230 ° C. for the surface layer of the long fiber web and 220 ° C. for the back layer side, and the apparent density was about 0.25 g / cm ³ at a linear pressure of 50 kg / cm ^3. After thermocompression bonding so that the solid content of the dimethylpolysiloxane is about 2 wt% of the solid content of the composition by spraying, it is dried at 140 ° C for 2 minutes, and then slit to a width of 4.2 m. Three types of primary base fabrics for tufted carpets were prepared in which the wear strength of the surface layer was 3.0 or higher and the wear strength of the back layer was 3.0 or lower.

Then, using a tufting machine,
Pile yarn (nylon BCF, 26
00 denier, 160 filaments) 1/10 gauge, 12 stitches / inch, pile height 3.5 mm, loops and tufts so that the pile yarn implantation width is about 4.1 m (the surface side of the primary base cloth is Pile side), after dyeing with a loop steamer type continuous dyeing machine, the end of the primary base cloth is gripped with a pin tenter and spread and dried at 130 ° C. so that the pile yarn implantation width becomes about 4.15 m. . Further, the following vinyl chloride backing resin composition (X) was applied to an endless belt in a thickness of 1.3 mm, and a glass fiber nonwoven fabric having a basis weight of 40 g / m 2 was impregnated on the endless belt, and the following vinyl chloride backing resin composition ( Y) to thickness 1.
The pile fabric (primary base fabric after tufting) which was preheated at about 100 ° C was laminated on top of it and coated with a vinyl chloride backing resin composition from the endless belt side at 175 ° C.
After heat-treatment, the mixture was cooled and cut into 50 cm square to prepare a tile carpet.

<Vinyl chloride backing resin composition (X)
＞ Vinyl chloride paste 100 parts by weight Dioctyl phthalate 90 parts by weight Calcium carbonate 350 parts by weight Carbon toner 2 parts by weight <Vinyl chloride backing resin composition (Y)> Vinyl chloride paste 100 parts by weight Dioctyl phthalate 95 parts by weight Calcium carbonate 300 parts by weight Carbon 2 parts by weight of toner Example 4 The low melting point polymer used for the surface layer of the long fiber web has a melting point of 1
94 ° C. adipic acid copolymerized polyester, the low melting point polymer used for the back layer is isophthalic acid copolymerized polyester having a melting point of 225 ° C., and the weight ratio of the high melting point polymer and the low melting point polymer is 85:15 for both the front and back layers. A primary base cloth for tufted carpet and a tile carpet were prepared under the same conditions as in Example 1 except that the embossing roll temperature was 220 ° C. for both the front and back layer side rolls.

Example 5 Primary conditions for tufted carpet were obtained under the same conditions as in Example 1 except that the fineness of the monofilament in the surface layer of the long fiber web was 5 denier and the fineness of the monofilament in the back layer was 10 denier. A base cloth and a tile carpet were created.

Examples 6 to 7 Polyethylene terephthalate having a melting point of 262 ° C. was used as a high-melting polymer and isophthalic acid having a melting point of 225 ° C. was used by using a spinning / fabric making apparatus capable of spray laminating two layers of fiber webs before and after. The acid-copolymerized polyester was used as a low-melting polymer and melted at 285 ° C. Then, the spinning machine in the front row (back layer) was mixed with a high-melting polymer fiber and a low-melting polymer fiber with a spinneret hole diameter of 0.5 mmφ and 30 holes. A large number of fine type spinnerets are arranged so that the weight ratio of the high melting point polymer and the low melting point polymer is 85:15, and the spinner in the rear row (surface layer) has a spinneret hole diameter of 0.5 mmφ and 30 holes. A large number of core-sheath composite type bases in which the high-melting polymer is on the core side and the low-melting polymer is on the sheath side are arranged and melted so that the weight ratio of the high-melting polymer and the low-melting polymer is 80:20. After the polymer was extruded and cooled, it was pulled at a high speed by an ejector so that the single yarn denier was 8 denier, charged by a collision plate mainly composed of lead, the filament bundle was opened, and then the core-sheath type composite fiber layer on the surface layer. Then, the mixed fiber fibers in the back layer were sprayed on a moving net conveyor so that the basis weight ratios of the mixed fiber layers were (1) 30:70 and (2) 50:50, and were collected in a width of 4.3 m.

Subsequently, the roll temperature was set to 22 for both the front and back layer side rolls by a pair of embossing rolls having a pressing area of 18%.
Apparent density is about 0.25g / cm at 0 ℃ and linear pressure of 50kg / cm.
After thermocompression bonding so as to be ³ , the dimethylpolysiloxane emulsion was sprayed to adhere the solid content of about 2 wt% to the constituent fibers and dried at 140 ° C for 2 minutes, and then slit to a width of 4.2 m. However, the wear strength of the surface layer is 3.0 grade or higher, and the wear strength of the back layer is 3.0 grade or lower 2
A variety of primary tufted carpet base fabrics were made.

Subsequently, in the same manner as in Example 1,
Created a tile carpet.

Example 8 The laminated web of the core-sheath type composite fiber layer and the mixed fiber layer of Example 6 was needle punched from the core-sheath type composite fiber layer side at a needle density of 100 times / cm ² , and then thermocompression-bonded with an embossing roll. A primary base cloth for tufted carpet and a tile carpet were prepared under the same conditions as in Example 6 except that the above was performed.

Example 9 The roll temperature of the pair of embossing rolls was set to 210 ° C. for both rolls on the front and back layers of the long fiber web, and after thermocompression bonding, the rolls were impregnated with an ethylene-vinyl acetate copolymer resin emulsion and the surface layer was dried using a hot air dryer. The conditions were the same as in Example 1 except that hot air of 160 ° C. was sent only from the side to migrate the ethylene-vinyl acetate copolymer resin to the surface layer side and the resin adhesion amount to the long fiber web was 10 wt%.
Primary tufted carpet fabrics and tile carpets were made.

Comparative Example 1 Under the same conditions as in Example 1, except that the weight ratio of the high melting point polymer to the low melting point polymer was 75:25 for both the front and back layers, and the embossing roll temperature was 235 ° C. for both the front and back layer side rolls. Primary tufted carpet fabrics and tile carpets were made.

At this time, the abrasion strength of the primary base fabric for tufted carpet was 4.5 grade for both the front and back layers.

Comparative Example 2 Under the same conditions as in Example 1 except that the weight ratio of the high melting point polymer to the low melting point polymer was 95: 5 for both the front and back layers and the embossing roll temperature was 220 ° C. for both the front and back layer side rolls.
Primary tufted carpet fabrics and tile carpets were made. At this time, the wear resistance of the primary base fabric for tufted carpet was 2.0 grade for both the front and back layers.

Comparative Example 3 In Example 1, a core-sheath composite type in which a high melting point polymer having a spinneret hole diameter of 0.5 mmφ and a hole number of 30 holes is a core side, and a low melting point polymer is a sheath side in a spinning device on both front and back layers side. Under the same conditions as in Example 1 except that a large number of spinnerets are arranged, the weight ratio of the high melting point polymer and the low melting point polymer is 80:20, and the embossing roll temperature is 230 ° C. for both the front and back layer side rolls. A primary carpet backing and a tile carpet were prepared. At this time, the wear strength of the primary base fabric for tufted carpet was 4.0 grade for both the front and back layers.

The characteristics of the primary base fabrics for tufted carpets of Examples 1 to 9 and Comparative Examples 1 to 3 are shown in Tables 1 and 2, and the workability and the characteristics of tile carpets are shown in Tables 3 and 4.

[Table 1]

[Table 2]

[Table 3]

[Table 4] As described above, as shown in Tables 3 and 4, the primary base fabrics for tufted carpets of Examples 1 to 9 have the abrasion resistance of the surface layer of 3 in particular.
Grades above and the wear strength of the backing layer below Grade 3 are characteristics required for tufted carpet processing as compared with Comparative Examples 1 to 3, which is the penetration resistance value of the tuft during tufting and the strength of pile fabric. In addition, the tufted carpet (tile carpet) using the primary base fabric of the present invention is excellent in both dimensional stability during continuous dyeing and durability, rigidity such as pile surface quality and pile pull-out strength. It was also excellent.

Examples 10 to 12 Polyethylene terephthalate having a melting point of 262 ° C. was used as a high-melting polymer and isophthalic acid having a melting point of 225 ° C. was used by using a spinning / fabric making apparatus capable of jet-laminating two layers of fiber webs. The acid-copolymerized polyester was used as a low melting point polymer and melted at 285 ° C., and then the spinneret had a spinneret hole diameter of 0.
A large number of high-melting point polymer fibers and low-melting point polymer fibers with 5 mmφ and 30 holes are arranged, and the weight ratios of the high-melting point polymer and low-melting point polymer in the front and back layers of the long fiber web are ( 1) Surface layer 85:15,
Back layer 85:15, (2) Surface layer 80:20, Back layer 85: 1
5, (3) After extruding and cooling the molten polymer so that the surface layer is 80:20 and the back layer is 90:10, the single yarn denier is pulled at a high speed by an ejector so that the denier is 2 denier.
Charged by a collision plate mainly composed of lead, opened the filament bundle, and then sprayed on a moving net conveyor 4.3 m
Collected in width. Continuously, the roll temperature was set to 235 ° C. on the surface layer of the long fiber web and 220 ° C. on the back layer side by a pair of embossing rolls with a compression area of 18%, and a linear pressure of 60 kg.
Thermocompression bonding is performed so that the apparent density is about 0.4 g / cm ^{3 at} / cm, and the wear strength of the surface layer is 3.0 or higher and the wear strength of the back layer is 3.0 or lower. 3 Created a variety of wall materials.

Example 13 A low melting point polymer used for the surface layer of a long fiber web has a melting point of 1
94 ° C. adipic acid copolymerized polyester, the low melting point polymer used for the back layer is isophthalic acid copolymerized polyester having a melting point of 225 ° C., and the weight ratio of the high melting point polymer and the low melting point polymer is 80:20 for both the front and back layers. A wall material was prepared under the same conditions as in Example 10 except that the embossing roll temperature was 220 ° C. for both the front and back layer side rolls.

Example 14 A wall material was produced under the same conditions as in Example 10 except that the fineness of the single fiber in the surface layer of the long fiber web was 1 denier and the fineness of the single fiber in the back layer was 5 denier. .

Examples 15 to 16 Polyethylene terephthalate having a melting point of 262 ° C. was used as a high melting point polymer and isophthalic acid having a melting point of 225 ° C. was used by using a spinning / fabric making apparatus capable of jet-laminating two layers of fiber webs before and after. The acid-copolymerized polyester was used as a low-melting polymer and melted at 285 ° C. Then, the spinning machine in the front row (back layer) was mixed with a high-melting polymer fiber and a low-melting polymer fiber with a spinneret hole diameter of 0.5 mmφ and 30 holes. A large number of fine type spinnerets are arranged so that the weight ratio of the high melting point polymer and the low melting point polymer is 85:15, and the spinner in the rear row (surface layer) has a spinneret hole diameter of 0.5 mmφ and 30 holes. Arrange a large number of core-sheath composite type bases in which the high melting point polymer is the core side and the low melting point polymer is the sheath side so that the weight ratio of the high melting point polymer and the low melting point polymer is 70:30. After the molten polymer was extruded and cooled, it was pulled at a high speed by an ejector so that the single yarn denier was 2 denier, charged by a collision plate mainly containing lead, and the filament bundle was opened, and then the core-sheath type composite fiber of the surface layer The mixture was sprayed on a moving net conveyor so that the basis weight ratios of the mixed fiber layers of the layer and the back layer were (1) 50:50 and (2) 80:20, and were collected with a width of 4.3 m. Then, by using a pair of embossing rolls having a crimping area of 18%, the roll temperature is set to 220 ° C. for both the front and back layer side rolls, and thermocompression bonding is performed at a linear pressure of 60 kg / cm to an apparent density of about 0.4 g / cm ^3. Two types of wall materials having a surface layer having an abrasion strength of 3.0 or higher and a back layer having an abrasion strength of 3.0 or less were prepared.

Example 17 The roll temperature of a pair of embossing rolls was set to 215 ° C. for both rolls of the long fiber web front and back layers, and after thermocompression bonding, the rolls were impregnated in an acrylic ester resin emulsion, and only the front layer side was dried using a hot air dryer. A wall material was prepared under the same conditions as in Example 10 except that hot air at 160 ° C. was sent to migrate the acrylic ester resin to the surface layer side and the resin adhesion amount to the long fiber web was set to 15%.

Example 18 A wall material was prepared in which a resin adhesive layer having a thickness of 0.5 mm was provided on the back layer side of the wall material of Example 14.

Comparative Example 4 Under the same conditions as in Example 10, except that the weight ratio of the high melting point polymer to the low melting point polymer was 75:25 in both the front and back layers, and the embossing roll temperature was 235 ° C. in both the front and back layer side rolls. I made a wall material. The abrasion strength at this time was 4.5 grade for both the front and back layers.

Comparative Example 5 Under the same conditions as in Example 10, except that the weight ratio of the high melting point polymer to the low melting point polymer was 95: 5 for both the front and back layers, and the embossing roll temperature was 220 ° C. for both the front and back layer side rolls. I made a wall material. At this time, the abrasion strength was 2.5 grade for both the front and back layers.

Comparative Example 6 In Example 10, a core-sheath composite type in which a spinning machine has a spinneret having a hole diameter of 0.5 mmφ and a hole number of 30 holes is a high melting point polymer and a low melting point polymer is a sheath side. Of the wall material under the same conditions as in Example 10 except that a large number of spinnerets were arranged, the weight ratio of the high melting point polymer and the low melting point polymer was 70:30, and the embossing roll temperature was 230 ° C. for both the front and back layer side rolls. It was created. The abrasion strength at this time was 5.0 grade for both the front and back layers.

The characteristics of the wall materials of Examples 10-19 and Comparative Examples 4-6 are shown in Tables 5-6.

[0079]

[Table 5]

[Table 6] As shown in Tables 5 and 6, the wall materials of Examples 10 to 19 are those of Comparative Examples 4 to 6 in which the surface layer has a wear strength of grade 3 or higher and the back layer has a wear strength of grade 3 or lower. The printing characteristics and resin adhesiveness of the surface were superior to those of.

[0080]

INDUSTRIAL APPLICABILITY The nonwoven fabric of the present invention, particularly the primary base fabric for carpets, for example, the primary base fabric for tufted carpet, should be satisfied in all the steps of carpet production such as tufting processability, dyeing processability and dimensional stability. Carpets that have a good balance of workability are used, and carpets that use this base cloth also have excellent durability and rigidity such as pile surface quality and pile thread pull-out strength. The material has an effect of having excellent surface printing characteristics and resin adhesiveness.

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Claims (27)

[Claims] 1. A long-fiber non-woven fabric in which a long-fiber web composed of a low-melting polymer and a high-melting polymer is fixed by heat fusion, and a difference in thermal adhesive strength is provided between front and back layers of the long-fiber non-woven fabric. Non-woven fabric characterized by. 2. The thermal bond strength of the surface layer of the long fiber nonwoven fabric is
The non-woven fabric according to claim 1, wherein the abrasion resistance of the surface layer measured according to the Taber method of the abrasion strength test of JIS L-1906 is grade 3 or higher. 3. The thermal adhesive strength of the back layer of the long fiber non-woven fabric is
The non-woven fabric according to claim 1, wherein the back layer has a wear strength of 3 grade or less, which is measured according to the Taber method of the wear strength test of JIS L-1906. 4. The difference in the thermal adhesive strength is JIS L-190.
The nonwoven fabric according to any one of claims 1 to 3, which is at least 0.5 grade or more when expressed by the abrasion strength measured according to the Taber type method of the abrasion strength test of No. 6. 5. The nonwoven fabric according to claim 1, wherein the content ratio of the low melting point polymer in the surface layer of the long fiber nonwoven fabric is higher than the content ratio of the low melting point polymer in the back layer. 6. The non-woven fabric according to claim 1, wherein a ratio of the high melting point polymer and the low melting point polymer in the surface layer of the long fiber non-woven fabric is 90:10 to 60:40. 7. The non-woven fabric according to claim 1, wherein the backing layer of the long-fiber non-woven fabric has a high-melting point polymer and a low-melting point polymer in a ratio of 95: 5 to 70:30. 8. The low melting point polymer contained in the surface layer of the long-fiber nonwoven fabric is composed of a polymer having a lower melting point than the low melting point polymer contained in the back layer. Non-woven fabric. 9. The continuous fiber non-woven fabric according to claim 1, wherein the fineness of the single fiber constituting the surface layer is smaller than the fineness of the single fiber constituting the back layer. Non-woven fabric. 10. A non-woven fabric layer (A) comprising a core-sheath type composite fiber having a surface layer of a high-melting point polymer in a core portion and a low-melting point polymer in a sheath portion of the long-fiber nonwoven fabric, and a back layer of the high-melting point polymer. The non-woven fabric according to any one of claims 1 to 9, which is composed of a non-woven fabric layer (B) made of a mixed fiber of a fiber made of (1) and a fiber made of a low-melting polymer. 11. The non-woven fabric layer (A) and the non-woven fabric layer (B)
The non-woven fabric according to claim 10, wherein the non-woven fabric is needle-punched. 12. The non-woven fabric according to claim 1, wherein the fibers of the long-fiber non-woven fabric are bonded and fixed with a resin binder. 13. The non-woven fabric according to claim 12, wherein the front and back layers of the long-fiber non-woven fabric are provided with a resin binder concentration gradient difference. 14. The melting point difference between the high melting point polymer and the low melting point polymer is in the range of 20 to 80 ° C.
The nonwoven fabric according to any one of 1 to 13. 15. The non-woven fabric according to claim 1, wherein the high melting point polymer is polyethylene terephthalate, and the low melting point polymer is a copolyester. 16. The non-woven fabric according to claim 1, wherein the long-fiber non-woven fabric has thermocompression-bonded parts in a total area of the pressure-bonded parts of 5 to 30% of the non-woven fabric area. 17. The nonwoven fabric according to claim 1, which has an apparent density of 0.15 to 0.4 g / cm.
Primary carpet base carpet characterized in that it is ³ . 18. The primary base cloth for carpet according to claim 17, wherein the non-woven fabric is composed of fibers having a single fiber fineness of 2 to 15 d. 19. The non-woven fabric according to claim 10, wherein the non-woven fabric layer (A) and the non-woven fabric layer (B) have a basis weight ratio of 1.
The primary base fabric for carpet according to claim 17, which is in the range of 0:90 to 60:40. 20. A carpet characterized in that a pile yarn is tufted on the primary carpet base fabric according to any one of claims 17 to 19 and has a backing layer made of a resin or a non-woven fabric. 21. The carpet according to claim 20, wherein the pile yarn side is a surface layer of the primary carpet base fabric and the backing side is a back layer of the primary carpet fabric. 22. The carpet according to claim 20, which is a tile carpet obtained by cutting the carpet into tiles. 23. The nonwoven fabric according to claim 1, which has an apparent density of 0.2 to 0.55 g / cm.
A wall material characterized by being ³ . 24. The non-woven fabric has a single fiber fineness of 0.5 to 6 d.
24. The wall material according to claim 23, wherein the wall material is composed of the fiber. 25. The non-woven fabric according to claim 10, wherein the non-woven fabric layer (A) and the non-woven fabric layer (B) have a areal weight ratio of 3.
The wall material according to any one of claims 23 to 24, which is in the range of 0:70 to 95: 5. 26. The wall material according to claim 23, wherein the surface layer of the non-woven fabric is printed or printed. 27. The wall material according to claim 23, further comprising a resin adhesive layer on a back layer of the nonwoven fabric.